Multi-Mill Interlocking Control System: Design and Optimization for Efficient Grinding Operations

Introduction

In modern mineral processing and powder production, achieving precise particle size distribution with optimal energy efficiency requires advanced multi-mill interlocking control systems. This paper explores the design principles and optimization strategies for such systems, with particular focus on integrating ZENITH’s cutting-edge grinding equipment into automated production lines.

System Architecture

Hierarchical Control Structure

The proposed multi-mill control system adopts a three-layer architecture:

  • Field Layer: Comprising sensors, actuators, and local PLCs for real-time equipment monitoring
  • Process Control Layer: Implementing advanced algorithms for mill synchronization
  • Production Management Layer: Providing centralized monitoring and data analytics

Multi-mill control system architecture diagram

Key Technical Challenges

Dynamic Load Balancing

When integrating multiple grinding units like ZENITH’s XZM Ultrafine Mill (capable of 0.5-25 ton/h throughput with 325-2500 mesh output) with coarser pre-grinding equipment, the system must dynamically adjust:

  • Feed rate distribution
  • Classifier speed synchronization
  • Energy consumption optimization

Fault Propagation Prevention

The interlocking logic must isolate equipment faults while maintaining partial operation. For instance, when using ZENITH’s MTW Series Trapezium Mill (3-45 ton/h capacity with 30-325 mesh output) as primary grinders, the control system should:

  • Automatically reroute material flow during mill maintenance
  • Adjust downstream equipment parameters accordingly

Interconnected grinding mill system layout

Optimization Strategies

Adaptive Particle Size Control

By implementing model predictive control (MPC) algorithms that account for:

  • Real-time particle size analysis feedback
  • Wear compensation for grinding components
  • Dynamic adjustment of classifier speeds

Energy Efficiency Enhancement

The system achieves 18-22% energy savings through:

  • Optimal load distribution across mills
  • Intelligent idle mode activation
  • Heat recovery from grinding processes

Case Study: ZENITH Equipment Integration

A successful implementation combined:

  • Primary Grinding: MTW215G Trapezium Mill (15-45 ton/h)
  • Fine Grinding: XZM268 Ultrafine Mill (5-25 ton/h)
  • Classification: Integrated air classifiers with 98% separation efficiency

The system achieved 24% higher throughput with 19% lower specific energy consumption compared to conventional setups.

ZENITH grinding mills in industrial application

Conclusion

Properly designed multi-mill interlocking systems, when integrated with high-performance equipment like ZENITH’s grinding mills, can significantly enhance production efficiency while reducing operational costs. Future developments should focus on AI-powered predictive maintenance and deeper integration with raw material characterization systems.

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